Prefabricated aggregated floor panel device and system and method for making and installing aggregated panels

ABSTRACT

A prefabricated terrazzo panel and system, method for making terrazzo panels and method for installing terrazzo panels wherein the panels comprise terrazzo epoxy, a top surface, a bottom surface, sides and a groove along each side and the panel system comprises a plurality of panels, locking strips that join adjacent panels and terrazzo or terrazzo-like filler for joining and creating a seamless joint between adjacent panels. The method of manufacturing the panels generally includes providing, installing and, or preparing borders on a flat, level horizontal structure, applying an epoxy primer having a high viscous to the supporting structure to prevent adherence, introducing previously prepared epoxy terrazzo or comparable aggregate mixture into the border volume, leveling the pour mixture, allowing it to cure, grinding the surface of the cured aggregate to a desired thickness, sanding and polishing the top surface, and cutting the cured terrazzo into panels having predetermined dimensions. The method of installing prefabricated terrazzo panels comprises applying an epoxy primer to the selected floor surface, applying a coat of setting material to the floor surface with a notched trowel, aligning and setting panels and locking strips on the prepared floor surface in a manner that places the locking strip heads in the panel grooves, filling any with a terrazzo epoxy filler or similar filler, allowing setting time, grinding the filler flush with the top surface of the panels and polishing the top surface of the panels and joints.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of provisional applicationSerial No. 60/388,993 filed Jun. 14, 2002.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] N/A

COPYRIGHT NOTICE

[0003] A portion of the disclosure of this patent document containsmaterial that is subject to copyright protection. The copyright ownerhas no objection to the facsimile reproduction by anyone of the patentdocument or patent disclosure as it appears in the Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightsrights whatsoever.

BACKGROUND OF THE INVENTION

[0004] 1. Field of the Invention

[0005] This invention relates generally to prefabricated aggregatedfloor panels, and more particularly, to a prefabricated terrazzo paneldevice and system and method for making and installing prefabricatedterrazzo panels.

[0006] 2. Description of the Background Art

[0007] Aggregate floors, such as terrazzo, are well known in the art.Terrazzo is a form of mosaic flooring that consists of small pieces ofmarble or granite set in mortar and given a high polish. Binding agentsare used to anchor marble, granite or other aggregate chips in theterrazzo floor. Three types of binders are used, which include cement,cement with an acrylic additive, and epoxy.

[0008] Terrazzo floors known in the art are poured and set on asupporting floor structure at the desired site of installation withinset boundaries. Conventional terrazzo flooring and methods for makingsame are expensive and time consuming. The costs and time involved increating terrazzo flooring are high because the floors must be formedand poured at the site of installation. Conventional methods forcreating terrazzo flooring do not include prefabricating terrazzopanels. Based on conventional techniques, terrazzo panels cannot beprefabricated because they adhere to the supporting substrate whencuring and are difficult to join without seams. If, however, terrazzopanels could be prefabricated off-site into panels it would facilitatemore cost and time effective installation. In addition, it would be evenmore attractive if prefabricated panels could be joined without seamsbetween their edges.

[0009] As noted in U.S. Pat. No. 5,339,589, terrazzo floors areconstructed in accordance with well-established principles and methods.Conventional methods include placing a foundation layer of materialcomposed of concrete on the ground or floor. A screed bed having dividerstrips are then installed over the foundation layer forming panels intowhich a mixture of cement, water and terrazzo aggregate is poured. Ascreed bed is a mixture of sand, cement and water and brings thefoundation substrate layer closer to level, absorbs horizontal movementbetween the building structure and the aggregate surface, and serves asa setting bed for the panel forming divider strips. The divider stripsserve as a gauge for leveling the floor and provide expansion joints andcontrol paths for cracks. The resulting pour must be quickly leveledwith a trowel to the top of strips. Thereafter matching aggregate issprinkled over the surface, which is then compacted and compressed withstatic rollers. The rollers force out any trapped air and excess cement,and compact the aggregate to the greatest possible density. Once themixture cures, it is polished so that the aggregate, usually marble,contained therein becomes decorative and formal in appearance.

[0010] This conventional process and similar processes havedisadvantages. For instance, the leveling and compacting of theaggregate must be completed in a limited period of time before curingbegins. Accordingly, a terrazzo floor must be poured in sections so thatone section can be completed before a new section is started. Inaddition, the floor must be poured on cite. Consequently, constructingterrazzo floors is slow and labor-intensive. Other attempts have beenmade to address the above noted drawbacks, but have failed to realizeadequate success. If a device and system existed that was more reliable,more efficient and less expensive it would be well received. The instantinvention addresses this unfulfilled need in the prior art.

BRIEF SUMMARY OF THE INVENTION

[0011] In light of the foregoing, it is an object of the presentinvention to provide a prefabricated terrazzo or terrazzo-like panel.

[0012] It is another object of the instant invention to provide aterrazzo panel that can be prefabricated prior to installation.

[0013] It is an additional object of the instant invention to provide aprocess for manufacturing prefabricated terrazzo or terrazzo-like panelsthat can be transported to and installed at a remote site.

[0014] It is also an object of the instant invention to provide a methodfor installing prefabricated terrazzo or terrazzo-like panels.

[0015] It is a further object of the instant invention to provide amethod for manufacturing prefabricated terrazzo or tertazzo-like panelsthat alleviates the problem of adherence to the supporting substrateduring the curing process.

[0016] It is an additional object of the instant invention to provide amethod for installing prefabricated terrazzo or terrazzo-like panelswith virtually no seams between adjacent panels.

[0017] It is another object of the instant invention to provide an oralpharyngeal evacuation endotracheal tube that has a central valve incommunication with a vacuum source for aspirating pooled secretionsabove the cuff.

[0018] It is a further object of the instant invention to provide alocking strip that facilitates the joining and seamless joining ofadjacent terrazzo or terrazzo-like panels.

[0019] In light of these and other objects, the instant inventioncomprises a prefabricated terrazzo panel and system, method for makingterrazzo panels and method for installing terrazzo panels. The panelscomprise terrazzo epoxy, a top surface, a bottom surface, sides and agroove along each side. The panels are fabricated from a terrazzo epoxyor terrazzo like material. The panel system comprises a plurality ofpanels, locking strips that join adjacent panels and terrazzo orterrazzo-like filler for joining and creating a seamless joint betweenadjacent panels. The system of the invention generally comprises aplurality of panels, locking strips for joining adjacent panels andterrazzo, terrazzo-like and, or epoxy filler adapted for providing aseamless joint. The method of manufacturing the panels generallycomprises providing, installing and, or preparing borders on a flat,level horizontal structure, applying an epoxy primer having a highviscous consistency similar to a paste to the supporting structure toprevent adherence of the terrazzo epoxy to the supporting structureduring curing, preparing and, or introducing previously prepared epoxyterrazzo or comparable aggregate mixture into the border volume,leveling the pour mixture, allowing it to cure, grinding the surface ofthe cured aggregate to a desired thickness, sanding and polishing thetop surface, and cutting the cured terrazzo into panels havingpredetermined dimensions and preparing the panels for installation. Themethod of installing prefabricated terrazzo panels comprises applying anepoxy primer to the selected floor surface, applying a coat of settingmaterial having fine powder and, or marble dust fillers that achieveproper consistency to the floor surface with a notched trowel, aligningand setting panels and locking strips on the prepared floor surface in amanner that places the locking strip heads in the panel grooves, fillingany voids including voids between panels with a terrazzo epoxy filler orsimilar filler, allow setting time, grinding the filler flush with thetop surface of the panels and polishing the top surface of the panelsand joints.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0020]FIG. 1 is a perspective view of the preferred embodiment of theprefabricated terrazzo panel in accordance with the instant invention.

[0021]FIG. 2 is an end view of the preferred embodiment of theprefabricated terrazzo panel in accordance with the instant invention.

[0022]FIG. 3 is a perspective view of the preferred embodiment of thelocking strip in accordance with the instant invention.

[0023]FIG. 4 is an end view of the preferred embodiment of the lockingstrip in accordance with the instant invention.

[0024]FIG. 5 is an end view of the preferred embodiment of theprefabricated terrazzo panel and locking strip as joined in accordancewith the instant invention.

[0025]FIG. 6 is an end view of the preferred embodiment of theprefabricated terrazzo panel and locking strip system in accordance withthe instant invention.

[0026]FIG. 7 is a perspective view of the preferred embodiment of thesystem for making prefabricated terrazzo panels in accordance with theinstant invention.

[0027]FIG. 8 is an end view of the preferred embodiment of the systemfor making prefabricated terrazzo panels in accordance with the instantinvention.

[0028]FIG. 9 is a plan view of an alternative embodiment of the systemfor making prefabricated terrazzo panels in accordance with the instantinvention.

[0029]FIG. 10 is a plan view of the alternative embodiment of theprefabricated terrazzo panel in accordance with the instant invention.

[0030]FIG. 11 is an end view of an alternative locking strip used inaccordance with the system of the instant invention.

[0031]FIG. 12 is an end view of the preferred embodiment of theprefabricated terrazzo panel and alternative locking strip in accordancewith the instant invention.

DETAILED DESCRIPTION OF THE INVENTION

[0032] With reference to the drawings, FIGS. 1-12 depict the preferredand alternative embodiments of the instant invention which is generallyreferenced as a prefabricated panel and, or system and, or method formaking and, or method for installing prefabricated panels and, or bynumeric character 10. Referring to FIGS. 1-12, the instant inventioncomprises a prefabricated panel or tile 10, panel system 10, 20, 30, 40,50 process and system for making aggregated floor panels 100, 110 andprocess for installing the prefabricated aggregated floor panels 10. Theprefabricated panels preferably comprise a terrazzo or terrazzo-basedtile that may be installed on a floor surface, wall surface or otherflat substrate. The panel system 10, 20, 30, 40, 50 comprises thecomponents used to form and that facilitate installation of the panels10, as shown in FIGS. 5, 6 and 12. The system for making the panels 10comprises the components that facilitate the manufacture of the panels10, as shown in FIGS. 7-9. The process for installing the prefabricatedterrazzo panels 10 is described herein.

[0033] With reference to FIGS. 1 and 2, the prefabricated panels 10comprise a tile substrate 11, top surface 12, bottom surface 14, sides15 and at least one groove 16 formed in and along at least one side 15.The tile substrate 11 preferably comprises an aggregate or terrazzomixture, such as epoxy terrazzo or aggregate having terrazzo-likespecifications. The groove 16 preferably extends along each side and mayextend completely across each side. Alternatively, the groove 16 mayextend partially across one or more of the sides 15. The panels 10 arepreferably at least substantially square or rectangular and have athickness of approximately one-quarter inch (1/4″) to three-eights inch(⅜″) or thicker. In an alternative embodiment, the panels 10 maycomprise alternative geometric shapes and, or dimensions. The groove(s)16 provide a track for receiving a portion of a locking strip 20 wheninterlocking adjacent panels 10 during the installation process. Thepanels 10 can be made in various sizes, such as four feet (4′) by fourfeet (4′), five feet (5′) by five feet (5′), six feet (6′) by six feet(6′), or other dimensions. The bottom surface 14 of the cured aggregatepanels 10 have a textured surface for facilitating bonding with a floorsurface. The prefabricated panels 10 preferably comprise small pieces ofmarble, granite or other known substitutes set in mortar and having ahigh polish finish. The dimensions noted herein may vary withoutdeparting from the scope and spirit of the instant invention.

[0034] With reference to FIGS. 1-6, the panel system of the instantinvention comprises a plurality of prefabricated panels 10 andcorresponding number of locking strips 20 that facilitate installation.The locking strip 20 comprises a base 21, apertures 26 formed in thebase 21, and a vertically projecting elongated tongue structure 22, asshown in FIGS. 3 and 4. The tongue structure 22 comprises a head 23 thatis joined to the base 21 by a stem structure 24 and has an approximateoverall height of 0.325 P.I. The head 23 has an approximate width of0.150 P.I. at the upper end and 0.250 P.I. at its lower or widest endand an approximate height of 0.210 P.I. The stem 24 has an approximateheight of 0.125 P.I. and width of 0.063 P.I. The angle of curvature atthe lower end of the head 23 is approximately twenty (20) degrees. Thesedimensions may vary in accordance with design specifications. The basehas an approximate thickness of 0.125 P.I. and width of 1.850 P.I. Thelocking strip 20 is manufactured with a custom prefabricated die in anextrusion process using plastic or a plastic-like material, such asthose comprising thermoplastic or thermosetting polymers that can bemolded, cast or extruded. The die forms the overall shape of the strip20. The locking strip 20 may alternatively comprise zinc, aluminum ormetals having properties similar to zinc and, or aluminum. A liquid,paste or pliable form of zinc or aluminum may be extruded through a die.The extrusion process produces the shape of the locking strip as shownin FIG. 4. The apertures 26 are punched through the base 21. The panelsystem may also comprise a coat of epoxy 40, preferably of a highviscous consistency that is similar to a wet paste and an epoxy primer30. The epoxy primer 30 is placed on the installation surface prior toapplying the epoxy 40.

[0035] With reference to FIGS. 11-12, the alternative locking strip 50comprises a projecting elongated tongue structure 52. The alternativetongue structure 52 comprises a head 53 that is joined to a stemstructure 54. The head 53 has an approximate width of 0.50 inches and anapproximate height of 0.125 inches. The alternative stem structure 54has an approximate height of 0.125 inches and width of 0.125 inches.These dimensions may vary in accordance with design specifications. Thealternative locking strip 50 is also preferably manufactured with acustom prefabricated die in an extrusion process using plastic or aplastic-like material, such as those comprising thermoplastic orthermosetting polymers that can be molded, cast or extruded. The dieforms the overall shape of the alternative strip 50. The alternativelocking strip 20 may also comprise zinc, aluminum or metals havingproperties similar to zinc and, or aluminum. A liquid, paste or pliableform of zinc or aluminum may be extruded through a die. The extrusionprocess produces the shape of the alternative locking strip as shown inFIG. 11. Unlike the preferred locking strip 20, the alternative lockingstrip's 50 head 53 is inverted and the stem 54 aligns at or near the topsurface of the panels 10 when installed, as shown in FIG. 12. Althoughthe preferred method for installation of aggregated floor panelsincludes the use of the preferred locking strip 20 and is described withreference to using preferred locking strip 20, the method ofinstallation may include the use of the alternative locking strip 50without departing from the scope and spirit of the instant invention.

[0036] With reference to FIGS. 7-10, the process and technology formanufacturing the panels 10 generally comprises providing, installingand, or preparing the manufacturing system 100, introducing the epoxyterrazzo or comparable aggregate mixture (generally referenced herein asan epoxy terrazzo mixture 13) into the manufacturing system 100,allowing it to cure, grinding the surface of the cured aggregate to adesired thickness, polishing, cutting the cured terrazzo into panels 10and preparing the panels 10 for installation. With reference to FIGS.7-9, the manufacturing system 100 comprises at least one frame 101preferably formed by a plurality of forms or partitions 102 having aninterior surface 104, and a base layer 106 of urethane, Plexiglas orother type of plastic laminate with similar properties, such as Lexan,that is placed on the support substrate 1 within the frame structure101. The base layer 106 is preferably formed with a liquid urethane thatis applied to the support substrate and cured. The liquid urethane isalso used to fill in cracks that form in the base layer 106 when tilepanels 10 are cut from the epoxy terrazzo deck 15. The interior surface104 is substantially flat. In an alternative embodiment the interiorsurface 104 may comprise an elongated, substantially horizontalcontoured projection for forming the groove 16 in the panel 10 duringthe manufacturing process.

[0037] Still referring to FIGS. 7-10, when making the aggregate panels10 in accordance with the invention it is necessary that the supportsubstrate 1 have a substantially or perfectly level and flat surface.The support substrate 1 is preferably made of a solid material such asconcrete. The base layer 106 separates the epoxy terrazzo mixture 13from the support substrate surface 1, prevents it from adhering to thesupport substrate surface 1 and has properties that allow the epoxyterrazzo mixture 13 to temporarily adhere to the base layer surface suchthat it can be released therefrom without damaging the cured aggregateor panel 10. The base layer 106 is adhered to the supporting substrate1, such as a concrete floor, and bonded thereto with an epoxy oradhesive 108 that prevents the base layer 106 from releasing.

[0038] Once the platform is secured on the support substrate 1, theepoxy terrazzo mixture 13 in a liquid form and with the aggregate mixedtherein can be applied to the base layer 106 within the frame structure101 until the desired thickness is reached and, or as required. Theaggregate mixture 13 preferably comprises a liquid form of epoxyterrazzo. Once the epoxy terrazzo mixture 13 has been poured andleveled, the mixture 13 cures for approximately eight (8) hours. Uponcompleting the curing process, the cured mixture 13 comprises one largesheet or deck-like structure 15. In one embodiment, the deck 15 maycomprise a thirty (30) foot by sixty (60) foot panel resulting in 1,800square feet of cured terrazzo. The next step is to grind the top surfaceof the terrazzo deck 15 until achieving a consistent thickness. Theterrazzo deck 15 is preferably grinded by an inline grinding andpolishing machine. The machine travels above the deck 15. Aftercompleting the grinding and polishing steps, the terrazzo aggregate 13is cut into panels 10. The panels 10 can be cut into various sizes andshapes depending upon request or installation requirements, such as4′×4′, 5′×5′ or 6′×6′. Thereafter, the panels 10 are removed easily fromthe frame 101 and base layer 106. The back of the panel 10 has a glossyfinish after curing. To remove the glossy finish, the panels 10 arelightly sanded to give them a texture finished that facilitate bondingwith the installation support surface, i.e. floor. After grinding,polishing and cutting the panels 10, the edges of the panels 10 areprofiled with a router bit specifically designed to form grooves 16 thatcorrespond to the shape of the locking strip tongue structure. Thegrooves 16 mate with the locking strip 20 tongue structure 22 in amanner that locks the panels 10 together to facilitate installation inthe field, as shown in FIGS. 5 and 6.

[0039] The prefabricated panels 10 are installed after floor preparationat the installation site is completed. With reference to FIG. 6, thefloor 2 is prepared with an epoxy primer 30 and then a coat of settingmaterial, such as epoxy 40, is applied to the floor 2 with a notchedtrowel. The setting material (epoxy) 40 preferably has a thickconsistency, such as mayonnaise, to allow the epoxy 40 to stand verticaluntil the panel 10 is applied to the floor 2. Proper consistency in theepoxy 40 is achieved by adding a fine type of powder, such as marbledust, to the epoxy 40 in its liquid form until the right consistency ismet. The panel 10 is set over the epoxy 40 with a locking strip 40 inplace. The panels 10 and strips 20 are installed simultaneously, whichlocks the system together.

[0040] With reference to FIGS. 9 and 10, an alternative panel 10′ isshown. The alternative panels 10′ are made with contoured edges tofacilitate mating of adjacent panels 10′. The contour edges provide moresurface area and structure for enhanced surface tension to accommodatean epoxy filler. During installation, the alternative panels 10′ are setnext to each other approximately one inch apart to form a gap. The gapbetween the panels 10′ are filled with an epoxy terrazzo, similar tothat used to form the panels 10′ and grinded and polished such that thejoined panels 10′ appear seamless. The alternative panels 10′ are madein an alternative frame structure 110 with alternative partitions 114,as shown in FIG. 9, with virtually the same process disclosed hereinwith respect to the preferred embodiment. The partitions 114 arecontoured to form the contoured edges in the panels 10′.

[0041] The instant invention has been shown and described herein in whatis considered to be the most practical and preferred embodiment. It isrecognized, however, that departures may be made therefrom within thescope of the invention and that obvious structural and/or functionalmodifications will occur to a person skilled in the art.

What is claimed is:
 1. An aggregated floor panel system, said systemcomprising: at least one substrate comprising at least a terrazzo-likematerial; said substrate having a top surface, bottom surface, aplurality of sides and predetermined dimensions; and a groove formed inat least one of said sides to facilitate joining to an adjacentsubstrate.
 2. A system as recited in claim 1, farther comprising: aplurality of substrates; and means for dividing and joining adjacentsubstrates.
 3. A system as recited in claim 2, wherein said dividing andjoining means comprises: a locking strip having a projecting tongueadapted for mating with said groove.
 4. A system as recited in claim 3,wherein said locking strip further comprises a stem having a width thatis smaller than a width of said tongue.
 5. A system as recited in claim2, wherein said locking strip further comprises: a perforated base.
 6. Asystem as recited in claim 2, wherein said locking strip is elongated.7. A system m as recited in claim 1, wherein said system comprises aplurality of substrates.
 8. A method for making at least oneterrazzo-based panel having at least one groove in at least one side,said method comprising the steps of: employing a frame on asubstantially flat and level surface having a volume and base layer of aplastic-based laminate therein, wherein said laminate has propertiesthat prevent permanent adhesion of an aggregate terrazzo-based mixturethereto; introducing a terrazzo epoxy based solution inside the volumeand onto said base layer; leveling said solution to a predeterminedheight and to establish a top surface; allowing said solution to curefor a predetermined period of time so as to form a substrate; andcutting said substrate into a plurality of panels having side edges andat least one predetermined shape.
 9. A method as recited in claim 8,further comprising the steps of: grinding said top surface until adesired thickness is achieved; and polishing said top surface after saidgrinding step.
 10. A method as recited in claim 9, further comprisingthe step of: profiling at least one of said side edges so as to defineat least one groove extending at least partially across said at leastone side edge, said profiled side edge having a cross sectional shapethat corresponds to a shape of a selected locking strip.
 11. A method asrecited in claim 9, further comprising the step of: sanding said topsurface.
 12. A method for installing a plurality of terrazzo-basedpanels having grooves in at least one side edge, said method comprisingthe steps of: (a) applying an epoxy primer to a surface on which panelsare intended to be installed; (b) applying an epoxy setting materialover said epoxy primer, said setting material having a thick consistencysimilar to mayonaisse; (c) installing a tongue portion of a lockingstrip in a corresponding groove in a panel; (d) placing said panel andlocking strip over and on said setting material; (e) aligning a secondpanel side edge groove with said locking strip in said first panel, saidsecond panel having a second locking strip installed in a second groovedefined by said second panel; (f) repeating steps a through e apredetermined number of times; (g) filling in any gaps in or betweensaid panels with a terrazzo epoxy corresponding the terrazzo epoxy usedto make said panels; and (h) sanding the top surface of said panels.